Hackaday · Creativity & design

Hand-Folding Curved Metal Lines

A method has been demonstrated for creating curved folds in sheet metal using only hand tools and patience, avoiding the need for specialized machinery.

The technique involves drilling numerous small holes along the desired fold lines. This perforating weakens the metal, similar to a score line, allowing it to be bent into complex curves more cleanly than with other methods.

This approach was developed to fabricate a curved aluminum cover for a Belly Tank Lakester, where all fold lines were curved. Attempts to create a shallow groove for folding resulted in the aluminum cracking.

The method of drilling holes allows the metal between each hole to bend effectively, forming the required curves. The resulting part has small perforations along the fold lines, which are not highly visible on the finished piece as it is mounted on the underside of the vehicle.

Some finishing work and straightening are still necessary, but the core challenge of creating the curved folds is addressed by this technique. Polishing can further improve the appearance of the finished part.

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